Assessment of Donlee 3000-Horsepower TurboFire XL Boiler · a microprocessor-based controller and boiler pressure sensor (GRI 1994). A water/steam mixture is formed as the water rises

F E D E R A L E N E R G Y M A N A G E M E N T P R O G R A M

Internet: http://www.eren.doe.gov/femp

TechnologyInstallationReview

A case study onenergy-efficienttechnologies

Prepared by theNew TechnologyDemonstrationProgram

No portion of this publi-cation may be alteredin any form without priorwritten consent from theU.S. Department of Energyand the authoring nationallaboratory.

The two-staged combustion coupledwith the cyclonic burner is pivotal to theunit’s efficiency and low NOx and COemissions. The cyclonic swirling flamedischarges combustion gases directly intothe watertube boiler section. The firing rateand fuel and air allowances are controlled bya microprocessor-based controller and boilerpressure sensor (GRI 1994). A water/steammixture is formed as the water rises from thebottom water header through the tubes in theboiler wall. The steam drum, designed as afiretube unit, has flue gases flowing throughtubes to provide heat transfer to the water inthe drum. An economizer utilizes the remain-ing heat in the flue gas to preheat the boilerfeedwater. Water is taken from the steam drumto the header by natural circulation generatedby the rising steam/water mixture. A steamquality that is greater than 99.5 % is producedas the steam flows through the separator at thetop of the drum.

This Technology Installation Review (TIR) describesthe TurboFire XL industrial boiler technologyand presents information on existing applica-tions, energy-saving mechanisms, installationrequirements, and relevant case studies.

BackgroundThe industrial sector consumed20,140 TBtu of energy in 1992,which is 37% of the totalenergy consumption in theUnited States. Natural gasaccounts for 45% of thisenergy use, and boiler sys-tems are the largest end usein the industrial sector. Boil-ers account for approximately40% of all industrial energy con-sumption for heat and power.

Thirty-six percent of boilers usenatural gas (EIA 1991). Industrial

boilers range in size from 125 to

Assessment of Donlee 3000-Horsepower TurboFireXL BoilerIndustrial boiler found to provide enhanced efficiency, low NOx emissions forcommercial and industrial applications

The package boiler concept has been aroundfor more than 60 years, and there are manytypes available. Boilers provide steam or hotwater for industrial and commercial use. TheTurboFireXL boiler, shown in the figure below,is a non-traditional boiler that combines firetubeand watertube technology. The boiler is housedin a cylindrical body encasing a combustionchamber with watertubes extending along thewaterwall. Donlee Technologies developedthe design with support from the Gas ResearchInstitute (GRI).

The watertube furnace section is connected tothe firetube convective section in the steamdrum by a turning box with the waterwall sideand end walls. The waterwall tubes have anoutlet leading to a top header that is connectedto the steam drum and two water inlets fromthe bottom water header. The turning boxend wall contains points to access the watertubefurnace section and the steam drum and firetubesections. The single-pass convective section islocated in the steam drum. The heat transfer isenhanced between the flue gas and the waterin the steam drum by the addition of turbulators(metal gas flow restrictors).

TurboFireXL Boiler Photo courtesy of Donlee Technologies

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occurs at reduced flame tempera-ture, the primary combustion tem-peratures are reduced in the stagedcombustion. The primary zonereduced gas temperature assists inminimizing the NOx formation inthe secondary stage.

In the primary zone burner, combus-tion air and fuel are mixed using across flow nozzle. The mixing isfurther improved by the enhancedrecirculation induced by the refrac-tory target orifice located at the sec-ondary air injection ring. By injectingsecondary air into the target orifice,good mixing of secondary air withthe primary zone gases is accom-plished. Low CO emissions andlow excess air over a high turndownrange (10:1) can be realized due tothe proper mixing in the stagedcyclonic burner. The turndown isthe ratio between full load outputand minimum load output. Having

2500 horsepower (hp). The watertubeand firetube are the two major typesof industrial boilers. Firetube boilersare used predominantly in applica-tions requiring pressures below300 psig and sizes ranging from100 to 750 hp. The stresses createdin the boiler’s combustion tube limitthe pressure and capacity.

The boiler’s combustion gases passthrough tubes surrounded by theboiler’s water. For high-pressure(up to 850 psig, 750 to 2500 hp) andhigh capacity (up to 90,000 lb/hr ofsteam) applications, watertube boil-ers are used. In watertube boilers,water circulates within externallyheated tubes. An advanced gas-firedsystem that is more fuel-efficientand aids in meeting stricter environ-mental regulation is needed.

The TurboFireXL boiler, a clean-burning combination watertube/firetube boiler, uses a convectivesteam drum and incorporates aunique cyclonic burner concept.This report describes results froman evaluation of the performanceof Donlee’s 3000-horsepowerTurboFireXL boiler. The evaluationindicates that the boiler maintainedefficiencies greater than 81% downto a 10:1 turndown (minimum-firing)operating on gas and oil. The NOxand CO2 emission levels remainedsignificantly lower than the EPA’srequirement and those of standardboilers. Emissions were lowest at theminimum-firing load for both fuels.

Technology DescriptionThe TurboFireXL boiler combineswatertube and firetube designswith a cyclonic burner and stagedcombustion system. The major partsof the boiler are shown in Figure 1.Technology information was extractedfrom the general description sectionof Donlee Technologies Inc.’s boilers’data manual.

Cyclonic CombustionStaged cyclonic combustion isexecuted in a cylindrical refractoryburner section by injecting primarycombustion air and fuel tangentiallyat high velocity through nozzle ports.The primary zone of the stagedcyclonic burner is fired fuel rich ina combustion process characterizedby intense swirl combustion flowand high internal recirculation.Combustion is completed by inject-ing secondary air through ports in arefractory ring in the waterwall sec-tion. The air staging of cyclonic com-bustion contributes to reducing NOxemissions in the boiler. Theoretically,fuel rich combustion of well-mixedair and fuel prevents the formationof NOx in the primary zone, since allthe oxygen in the air is burned in thecombustion of the fuel. Thus nooxygen is available to react with thenitrogen in the air to form nitrogenoxides. Since fuel rich combustion

Figure 1. TurboFireXL boiler cutaway.

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a high turndown reduces the fre-quency of on/off cycling.

NOx formation is further reducedby the steam injection system (up to80% possible reduction) located inthe staged cyclonic burner. The steamis injected with natural gas into theprimary zone of the burner and causesa lower local flame temperature. Theinjection of a small amount of steam(less than 0.05 lb of steam per ft3 offuel flow) achieves NOx emissions< 25 ppm and slightly reduces theboiler efficiency (typically—3–10%).For oil firing, steam is injected throughthe swirler and annulus area of theoil gun. Other industry methodsof NOx reduction are low excess air(natural gas fuel only—5-10% reduc-tion), flue gas recirculation (60–70%reduction), and selective catalyticreduction (SCR—up to 90%).

The cyclonic combustion has a sig-nificant convective heat transfercomponent resulting from theswirling cyclonic flow, whichincreases the heat transfer. Thisincreased heat flux reduces thesurface area needed to generatethe required steam.

Watertube Wall BoilerThe waterwall boiler section is acylindrically shaped container. Itcontains 2-inch-diameter waterwalltubes on 3-inch center-to-centers. Agas-tight design for the high-pressureoperation and containment of fluegases is achieved by waterwall tubescontinuously seal-welded to a finmembrane. The watertubes form awishbone configuration with oneoutlet connection for steam/watermixture to a steam drum and twoinlet connections for water from abottom water header. The wishboneconfiguration promotes circulationof the steam/water mixture in themembrane tubes to the steam drum.The bottom water header is protected

from the flame impingement byremovable cast refractory blocks.

The refractory burner section isflanged to the watertube wall. Thesecondary air section is seal-weldedto the watertube wall. The targetorifice in the waterwall is attached inthe secondary air section. A turningbox with watertube side walls andend walls connects the watertubeboiler section and the firetube sec-tion in the steam drum. The turningbox waterwall tubes also have awishbone configuration with an out-let to a top header that connects withthe steam drum and two water inletsfrom the bottom water header. Aman-way to access the watertubeboiler section is located at the endwall of the turning box. In addition,there are two viewing ports; oneport gives a view of the flame fromthe burner and the other provides aview of the furnace and flame fromthe rear turning box.

Turning Box and EconomizerThe watertube wall design of the sidesof the turning box between the water-wall section and the steam drum pro-vides additional heat transfer surfacesfrom the flue gas to the water-steammixture (which increases boiler effi-ciency) and reduces refractory.

Standard and optional economizersare available based on site require-ments. The standard economizer is afinned tube integral design, incorpo-rating several parallel serpentine coils,connected to common top and bot-tom headers. The inlet and outlet ofeach coil are welded to a curved plate,and the plate is fitted onto the shell.Spacers that provide additional sup-port and maintain spacing for the fluegas are welded between the elbowsof each economizer coil. The fluegas is prevented from bypassing theeconomizer by flow diverters. Asuperheater, consisting of a compact

serpentine tube array, is located inthe turning box. The superheater isoptional but helps produce higheroverall steam generation efficiencies.

Burner and Steam DrumThe burner chamber has 10 to 14 airports depending on the boiler size.The cyclonic burner has a cross-flownozzle mixing design. Ports for thepilot, flame scanner, and optional oil-firing nozzle are in the burner frontcover. The secondary air ports arelocated in the target orifice and theports are tangential to the innerdiameter of the orifice.

The internal components of the steamdrum include a steam separator andconvective tubes with option for achemical feed and surface blowoffsystem. The convective tube bankfurther heats the steam/water mix-ture before releasing it to the steamoutlet through the steam separatorat the top of the drum. The separatoris installed against the crown of thesteam drum to provide maximumwater/steam disengagement height.Typically, the internal surface of theconvection tubes is ribbed to promoteheat transfer. The diameter of thetubes is 2.5 inches for 30,000 lb/hrand 3 inches for 65,000 lb/hr and100,000 lb/hr boiler units.

Case StudiesTurboFireXL boilers can be usedin any application where tradi-tional boilers have been used.This advanced natural-gas-firedboiler was developed for industrialand commercial use. This sectionbriefly highlights three applicationswhere the TurboFireXL boilers arebeing used. The first installation is a1000-hp TurboFireXL field test unitat Knouse Foods’ Peach Glen facilityin Pennsylvania installed in 1992.Knouse uses its boiler for the steril-ization of fruit and for heating the


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plant and administrative offices.The boiler produces 34,500 lb/hr ofsteam at a pressure of 125 psig withsteam quality greater than 99.5%.The steam quality exceeds the cleansteam specifications of the food pro-cessing industry. The boiler heats theentire building when it is operatingat 75% output and is saving $400/dayin heating costs during peak periodof operation and up to $90,000 annu-ally on steam generation. The boileris supplying the function that twotraditional boilers supplied in thepast. The Knouse boiler operates atan average efficiency of 85% over aturndown ratio of 10 to 1 with fullmodulation. The integral econo-mizer of the boiler helps meet theefficiency requirements. Boiler start-up takes 30 to 45 minutes.

The second boiler is located at a papermill owned by Cascades NiagaraFalls, Inc., in New York. The 1800-hpboiler was installed in 1993 primarilyas a steam source (60,000 lb/hr ofsteam). The third is a 3000-hp unit(100,000 lb/hr of steam) that has beenconstructed for SCM Chemicals inAshtabula, Ohio. The unit is designedto operate at 250 psig and producesuperheated steam at above 600°F(GRI 1994; Donlee).

Energy-Saving Mechanismsand BenefitsIndustrial steam boilers consumed2.6 quads (~30%) of the 8.9 quads ofnatural gas consumed in the UnitedStates in 1994. Industrial boilers rangein size from 125 to 2500 hp. The water-tube and firetube are the two majortypes of industrial boilers. Firetubeboilers are used predominantly inapplications requiring pressuresbelow 300 psig and sizes ranging from100 to 750 hp. The stresses created inthe boiler’s combustion tube limit thepressure and capacity. The boiler’scombustion gases pass through tubes

surrounded by the boiler’s water.For high-pressure (up to 850 psig, 750to 2500 hp) and high-capacity (up to90,000 lb/hr of steam) applications,watertube boilers are used. In water-tube boilers, water circulates withinexternally heated tubes. An advancedgas-fired system that is more fuel-efficient and aids in meeting stricterenvironmental regulations is needed.The TurboFireXL boiler, a combinationwatertube/firetube boiler, uses a con-vective steam drum and incorporatesa unique cyclonic burner concept.

The Donlee Technologies TurboFireXLmodels are packaged compact units.The boiler capacity ranges from1000 to 3000 hp providing 34,500to 100,000 lb/hr of steam at pressures upto 650 psig. Its compactness reducesthe space requirement and lowers theinstallation costs. The cyclonic swirl-ing flame provides superior mixingof fuel gas and combustion air whilefurnishing high convective heat trans-fer. The boiler offers a quick start-upand maintains high efficiency duringrapid response load change and lowemissions of nitrogen oxides (NOx≤ 30 [gas], 59 [oil] parts per million[ppm]) and carbon monoxide (CO≤ 20 [gas] 31 [oil] ppm). The low NOxemission level meets stricter require-ments by some states. The unit pro-vides good steam quality (99.5%) andthe boiler efficiency remains above81% during fall capacity down to 10%of rated capacity.

Federal Sector Potential

Technology Screening ProcessA feasibility assessment is needed tojustify the hardware required at tar-geted sites. Assessment activitiesmay include the following:

• Determine relevant specifications(thermal, physical, environmental,operational, and economical) ofthe TurboFireXL boiler.

• Collect energy expenditure, emis-sions, time-dependent energy(steam) usage.

• Survey facilities where boilerswill be used and devise site-selection criteria.

• Conduct life-cycle analyses usingthe boiler technology.

• Develop test and implementationplans for boilers.

Costs and InstallationDonlee manufactures three packagedboilers, and their costs are $250,000(1000 hp), $370,000 (1800 hp), and$590,000 (3000 hp). The installationcost varies based on the site conditionsfrom $50,000 to $100,000 (1000 hp),$100,000 to $150,000 (1800 hp), and$150,000 to $200,000 (3000 hp). Hence,the total installation cost varies from$300,000 to $790,000.

Technology PerformanceKnouse Foods’ Peach Glen facilityin Pennsylvania is a fruit processingcompany that uses steam primarilyto process, heat, and sterilize fruit.Also, the company uses steam forclean-up and to heat the plant andadministrative offices. The steamrequirement is 35,000 lb/hr operatingat 125 psig with an 8 to 1 or greaterturndown. A 1000-hp TurboFireXLwas installed in 1992 with a 25 1/2 -inch-diameter stack

After four years of operation, yearlyinspections of the boiler revealed nowatertube problems. The high circu-lation in the watertubes limits thepotential for corrosion. In addition,the startup time was reduced from3 hours to 30 to 45 minutes. Theboiler complies with environmentalsafety regulations in the Clean AirAct Amendments of 1990. The NOxemissions level was maintained atless than 30 ppm attributed to theboiler cyclonic burner technology. A


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cyclone of swirling flames and hotgases is formed in the boiler’s furnacecreating an optimum mix of fuel andair. Injecting steam into the combus-tion zone reduces NOx formationfurther and eliminates the need fora NOx removal system can.

Two problems were encountered afterthe boiler was installed. The firstproblem was the high level of noisegenerated by the fan. The 100-hpfan required insulation to reduce thenoise to a tolerable level. Cycling ofthe boiler during low steam demandperiods was the second problem.This occurred during weekendsduring process down time and lowspace heating requirements.

The problem was resolved by decreas-ing the low firing rate and attainingmaximum turndown capacity.Another change made was addinga single element control that used adifferential pressure transducer tofurther control feedwater. The con-trol helped to regulate boiler waterin the steam drum more evenly dur-ing rapidly changing steam demand.Over the five years period the boilerhas been operating, it has revealedthat it can respond in seconds tochanges in load demand from 8,000to 32,000 lb/hr throughout the daywithout damaging the boiler. Also,

throughout load demand the steamquality (99.5%) is maintained.

Technology DemonstrationA technology demonstration projecton a TurboFireXL boiler (3000 hp)was conducted at the Donlee facility,York, Pennsylvania, for LockheedMartin Energy Systems, Inc., OakRidge, Tennessee, on April 22 and 23,1999. The objectives of the projectwere to measure the environmentalimpact and efficiency performanceof the boiler. The combustion ofnatural gas and No.2 oil in boilersresults in the following nine emissions:nitrogen, oxygen, water, carbon diox-ide, particulate, carbon monoxide,nitrogen oxide, sulfur oxides, andvolatile organic compounds. Thelatter five emissions are classified aspollutants. These pollutants weremeasured by sampling the boilerstack exhaust while operating atminimum, 25%, 50%, 75%, and 100%loads except for the particulate whichwas measured at 100% using naturalgas and 50% and 100% using No.2oil. The percent load on the boilerwas based on fuel flow. EnvisageEnvironmental conducted emissionsampling, and Schmidt Associatesperformed ASME efficiency testconcurrently to emission sampling.

Emissions ResultsThe sample collection and analysistechniques utilized for emissiontests were performed in accordancewith USEPA Reference test methods1, 2, 3, 4, 5, 7E, 10, and 25A, whichare listed in the box on the followingpage. Sample points were at twoseparate traverses located at 1, 2.9,5.2, 7.8, 11, 15.7, 28.3, 33, 36.2, 38.8,41.1, and 43 inches in from the innerwall of the 44-inch-diameter stack.Therefore, there was a total of24 points, twelve at each traverse.Estimates of EPA AP-42 emissionsfor natural gas and No. 2 fuel oil arepresented in Table 1. The emissionswere sampled every minute andaveraged over the periods shownin Table 2.

Natural gas-fired emission test resultsare shown in Tables 2, 3, and 9 (seeAppendix A). The gas-fired resultsreveal NOx emissions ≤ 30.3 ppmfor the five firing loads tested. Theseresults are nearly analogous to themanufacturer’s predicted NOx emis-sions of less than 30 ppm, which issignificantly less than EPA AP-42factors of 112 ppm, as shown inTable 2 and Figure 2. The highestemissions level was recorded at 100%load (30.3 ppm) while the lowest

Figure 2. TurboFireXL emissions versus EPA factors (natural gas).

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level was at low load (16.3 ppm).Table 3 reveals an NOx emission rateof less than 0.004 lb/MMBtu (EPA)for all firing loads. This is substan-tially less than EPA’s emission limitof 0.86 lb/MMBtu (EPA) for cycloneboilers. The manufacturer predictedCO emissions to be less than 50 ppm,and the tests revealed actual CO emis-sions to be less than 21 ppm, which issubstantially lower than the Table 1and Figure 2 factor of 46 ppm andthe predicted value. The highestCO emissions level was at 25% load(20.5 ppm) and the lowest was atminimum load (11.1 ppm). Othermanufacturers’ comparable boilersgenerate emissions levels of approxi-mately 100 ppm operating conven-tionally and less than 40 ppm withflue gas recirculation. These compa-rable boilers can be retrofitted withselective catalytic reduction (SCR)units to reduce the emissions levelto below 20 ppm, but the SCR unitis expensive (Donlee and CleaverBrooks). In comparing the emissionsof other pollutants in Tables 2 and 3(VOCs and particulate) to EPA’s fac-tors in Table 1, these pollutant emis-sions are considerably less than EPA’sfactor limits.

No. 2 fuel oil results are presented inTables 4, 5, and 10 (see Appendix A),and graphically depicted in Figure 3.

NOx emissions levels varied from31.2 ppm to 59.2 ppm. The 75% loadyields the highest emissions level, andthe minimum load yields the lowestemissions level. The maximum NOxemissions rate was 0.008 lb/MMBtu(Table 5), which is significantly lessthan EPA’s limit of 0.86 lb/MMBtufor cyclone boilers (EPA). The pol-lutants generated (Tables 4 and 5) areall noticeably below EPA’s emissionfactors for fuel oil shown in Table 1.The CO emissions remained lessthan 31 ppm, which is smaller thanthe manufacturer’s projection of lessthan 50 ppm.

Performance ResultsThe boiler efficiency represents thedifference between the energy inputand output. The boiler efficiencywas computed by utilizing ASMEPower Test Code, PTC 4.1, for deter-mining the fuel-to-steam efficiencyapplying the heat loss method. Theadjustments for the injected steamused for NOx control was the onlydeviation from the ASME PTC 4.1method. In all cases except one, theinjected steam enthalpy was greaterthan the flue gas moisture enthalpy,resulting in a slightly higher efficiency.

USEPA Reference Test MethodsUSEPA Method 1 Sample and velocity traverses for stationary sources

USEPA Method 2 Determination of stack gas velocity and volumetric flow rate

USEPA Method 3 Gas analysis for carbon dioxide, oxygen, excess air, and dry molecularweight

USEPA Method 4 Determination of moisture content in stack gases

USEPA Method 5 Determination of particulate emissions from stationary sources

USEPA Method 7E Determination of nitrogen oxides emissions from stationary sources(instrumental analyzer procedure)

USEPA Method 10 Determination of carbon monoxide emissions from stationary sources(instrumental analyzer procedure)

USEPA Method 25A Determination of total gaseous organic concentrations using a flameionization analyzer

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Figure 3. TurboFireXL emissions versus EPA factors (No. 2 oil).


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The heat loss method is a heat bal-ance efficiency, which accounts forall the heat losses of the boiler bysubtracting from 100 percent thetotal percent of stack, radiation, andconvection losses. The stack tempera-ture indicates moisture loss and heatcarried away in the dry flue gases.Lower stack temperature revealsmore effective heat exchange andhigher fuel-to-steam efficiency. Airflow across (convection) and heatradiating (radiation) from the boilerare essentially constant throughoutthe firing range of a boiler.

Some other key factors that affect theboiler efficiency are excess air andambient air temperature. Excess airis additional air supplied to the burnerabove that required to complete com-bustion. Although this excess air isneeded to ensure sufficient air tomaintain safety, it reduces the boilerefficiency by extracting potentialenergy that could be used for heat-ing water. A minimum of 15% excessair is recommended. In this demon-stration project, the excess air rangedfrom 30.35% at minimum load to6% at 100% load using natural gasand 76.34% at minimum load and17.20% at 100% load using No. 2 oil

(see Tables 6 and 7, Figure 4). Thedata reveals the effect that increas-ing the percent of excess air has onthe efficiency. The efficiency dropsby 3.52% when the excess air isincreased from 6 to 30.35% usingnatural gas and 3.94% using No.2oil. These efficiency reductions arealso influenced by the increasedpercentage of steam injected. Eventhough the percent of excess air isgreater than 15% for all No.2 oilloads, the boiler efficiency remainsabove 80%. Conventional boilershave approximate 80% efficiencyat high-load, but efficiency typicallydecreases with turndown.

The predicted efficiency was 82% ±1% from 25 to 100% load firing natu-ral gas, but as seen in Table 6, the testresults exceeded the predicted effi-ciency. The largest sources of losseswere due to stack temperature (drygas heat) and moisture from com-bustion of hydrogen. The fuels had12.19% (No.2 oil) and 23.85% (naturalgas) hydrogen, as shown in Table 8.Therefore, No.2 oil incurs less lossdue to the combustion of hydrogen,which results in higher No.2 oil boilerefficiencies.

ManufacturerDonlee Technologies Inc., 693 NorthHills Road, York, Pennsylvania17402-2211.

ReferencesASME Power Test Code, PTC 4.1 –1964 (revised 1991), New York.

Cleaver Brook. www.cleaver-brooks.com, Wisconsin.

Donlee Technologies Inc. DonleeTurboFire XL Project Summary,Pennsylvania.

Energy Information Administration(EIA), U.S. Department of Energy. 1991.Core Databook, Washington, D.C.

U.S. Environmental ProtectionAgency (EPA). 1986. EPA AP-42,Washington, D.C.

U.S. Environmental ProtectionAgency (EPA). 1996. www.epa.gov/acidrain/NOx, Washington, D. C.

Gas Research Institute (GRI). 1994.Advanced Industrial Steam Boiler,Illinois.

Figure 4. TurboFireXL boiler efficiency.

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Table 1. AP-42 Uncontrolled Emission Factors (10-100 MMBtu/hr Boilers, Cleaver Brooks).

Table 2. Emissions Laboratory Summary Data (Natural Gas Fired).

Table 3. Gas Fired Total Emission Rate (Moisture and Particulate).

Table 4. Emissions Laboratory Summary Data (No. 2 Oil Fired).

Table 5. No. 2 Oil Fired Total Emission Rate (Moisture and Particulate).

Table 6. Natural Gas Efficiency Test Results.

Table 7. No. 2 Oil Efficiency Test Results.

Table 8. Fuel Ultimate Analysis (As Received).

Table 9. Detailed Gas Fired Emission Test Results (Moisture and Particulate).

Table 10. Detailed No. 2 Oil Fired Test Results (Moisture and Particulate).

Appendix A


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Table 1. AP-42 Uncontrolled Emission Factors (10-100 MMBtu/hr Boilers, Cleaver Brooks).

Fuel Units Particulate SO2 [SO3] CO NO2 VOCs VOCs

Nonmethane Methane

Natural Gas lb/MMBtu 0.00095-0.0048 0.00057 0.033 0.133 0.0027 0.0029

ppm na 0.34 46 112 6.8 7.3

Fuel Oil lb/MMBturesidual 0.649(%S)+0.0195 1.02(%S) [0.013(%S)] 0.0325 0.357 0.0018 0.0065

lb/MMBtudistillate 0.0143 1.01(%S) [0.013(%S)] 0.0325 0.143 0.0014 0.0004

ppmresidual na 549(%S) [7(%S)] 42 273 3.6 13

ppmdistillate na 544(%S) [7(%S)] 42 107 2.8 0.8


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Table 2. Emissions Laboratory Summary Data (Natural Gas Fired).

Date: April 22, 1999 Symbol (Units) Minimum Load 25% Load 50% Load 75% Load 100% Load

Sampling Time t (minutes) 45.0 40.0 40.0 40.0 60

Barometric Pressure Pb (in. Hg) 29.97 29.97 29.97 29.97 29.97

Static Pressure Pg (in. H2O) -0.06 -0.05 -0.15 -0.17 -0.17

Stack Pressure Ps (in. Hg) 29.97 29.97 29.96 29.96 29.96

Gas Meter Volume Vm (ft3) 32.18 28.51 28.33 28.07 54.54

Stack Area A (ft2) 10.56 10.56 10.56 10.56 10.56

Nozzle Diameter Dn (dec. in.) na na na na 0.32

“Y” Factor 0.994 0.994 0.994 0.994 0.994

Meter Temperature (oF) 67.9 82.2 80.4 78.6 72.5

Tm (oR) 527.9 542.2 540.4 538.6 532.5

Stack Temperature (oF) 217.5 181.5 228.0 247.1 248.29

Ts (oR) 677.5 641.5 688.0 707.1 708.29

Velocity Head (SQRT) P (in. H2O) 0.166 0.251 0.446 0.731 0.8

Orifice Pressure H (in. H2O) 1.66 1.66 1.66 1.66 3.01

Carbon dioxide CO2 (%) 6.8 9.3 10.4 10.3 10.8

Oxygen O2 (%) 8.9 4.4 2.5 2.8 1.8

Carbon monoxide CO (%) 0.0 0.0 0.0 0.0 0

Nitrogen N2 (%) 84.3 86.3 87.1 87.0 87.4

Pitot Coefficient Cp 0.84 0.84 0.84 0.84 0.84

Water Collected Vlc (ml) 192.8 191.8 160.1 162.1 258.5

Sample Weight: Mn

Probe (g) na na na na 0.0064

Filter (g) na na na na 0.0081

Impingers (g) na na na na 0.1074

NOx (ppm) 16.3 25.3 25.6 26.0 30.3

VOC as Propane (ppm propane) 0.0 0.1 0.0 0.1 0.1935

VOC as Carbon (ppm carbon) 0.0 0.4 0.1 0.4 0.5805

CO (ppm) 11.1 20.5 16.9 11.5 17.5

O2 (ppm) 89,000 44,000 25,000 28,000 18,000


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Table 3. Gas Fired Total Emission Rate (Moisture and Particulate).

Total Emissions Minimum Load 25% Load 50% Load 75% Load 100% Load

Particulate

lb/MMBtu na na na na 0.00067

lb/hr na na na na 0.72194

grains/dscf na na na na 0.00410

Nitric Oxides

lb/MMBtu 0.0035 0.0040 0.0036 0.0037 0.0041

lb/hour 0.4915 1.1521 2.0634 3.3749 4.4593

lb/dscf 1.94E-06 3.02E-06 3.06E-06 3.10E-06 3.62E-06

Total VOC’s

lb/MMBtu 0.00E+00 1.49E-05 5.27E-06 1.34E-05 2.05E-05

lb/hour 0.0000 0.0043 0.0030 0.0121 0.0222

lb/dscf 0.00E+00 1.13E-08 4.46E-09 1.11E-08 1.8E-08

Carbon Monoxide

lb/MMBtu 1.46E-03 1.96E-03 1.45E-03 1.00E-03 0.001447

lb/hour 0.2041 0.5681 0.8289 0.9102 1.5674

lb/dscf 8.07E-07 1.49E-06 1.23E-06 8.36E-07 1.27E-06

System Flow Rates

ft/sec 10.92 16.11 29.36 48.89 53.13

ACFM 6,919 10,204 18,604 30,974 33,660

DSCFM 4,218 6,356 11,251 18,153 20,543

Moisture Content (%Volume) 21.90 24.43 21.30 21.61 18.23

Sample Location Temp. (oF) 218 182 228 247 248


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Table 4. Emissions Laboratory Summary Data (No. 2 Oil Fired).

Date: April 23, 1999 Symbol (Units) Minimum Load 25% Load 50% Load 75% Load 100% Load

Sampling Time t (minutes) 35 35 60.0 35 30.0

Barometric Pressure Pb (in. Hg) 29.91 29.91 29.91 29.91 29.91

Static Pressure Pg (in. H2O) 0.02 0.03 0.00 0.00 0.00

Stack Pressure Ps (in. Hg) 29.91 29.91 29.91 29.91 29.91

Gas Meter Volume Vm (ft3) 26.69 25.55 41.88 25.50 45.10

Stack Area A (ft2) 10.56 10.56 10.56 10.56 10.56

Nozzle Diameter Dn (dec. in.) na na 0.32 na 0.32

“Y” Factor 0.996 0.996 0.996 0.996 0.996

Meter Temperature (oF) 60.1 58.9 59.1 57.9 63.5

Tm (oR) 520.1 518.9 519.1 517.9 523.5

Stack Temperature (oF) 152.8 182.6 251.7 255.8 259.8

Ts (oR) 612.8 642.6 711.7 715.8 719.8

Velocity Head (SQRT) P (in. H2O) 0.260 0.334 0.510 0.963 1.350

Orifice Pressure H (in. H2O) 1.80 1.80 1.57 1.80 8.03

Carbon dioxide CO2 (%) 5.9 6.2 8.1 8.6 9.8

Oxygen O2 (%) 10.5 9.8 6.6 5.6 3.6

Carbon monoxide CO (%) 0.0 0.0 0.0 0.0 0.0

Nitrogen N2 (%) 83.6 84.0 85.3 85.8 86.6

Pitot Coefficient Cp 0.84 0.84 0.84 0.84 0.84

Water Collected Vlc (ml) 82.6 87.2 193.3 109.8 216.7

Sample Weight: Mn

Probe (g) na na 0.0062 na 0.0079

Filter (g) na na 0.0081 na 0.0440

Impingers (g) na na 0.4858 na 0.1979

NOx (ppm) 31.2 35.8 48.9 59.2 53.3

VOC as Propane (ppm propane) 0.0 0.1 0.9 0.1 0.5

VOC as Carbon (ppm carbon) 0.0 0.3 2.7 0.3 1.5

CO (ppm) 10.0 15.1 22.0 31.0 14.8

O2 (ppm) 105,000.0 98,000.0 66,000.0 56,000.0 36,000.0


13

Table 5. No. 2 Oil Fired Total Emission Rate (Moisture and Particulate).

Total Emissions Minimum Load 25% Load 50% Load 75% Load 100% Load

Particulate

lb/MMBtu na na 0.00112 na 0.00310

lb/hour na na 0.58 na 5.10

Grains/dscf na na 0.0052 na 0.0173

Nitric Oxides

lb/MMBtu 0.00777 0.00837 0.00889 0.01004 0.00800

lb/hour 1.7035 2.4305 4.6227 10.6353 13.1648

lb/dscf 3.72E-06 4.27E-06 5.84E-06 7.07E-06 6.36E-06

Total VOCs

lb/MMBtu 0.00E+00 1.73E-05 1.28E-04 1.26E-05 5.84E-05

lb/hour 0.0000 0.0050 0.0665 0.01 0.0961

lb/dscf 0.00E+00 8.85E-09 8.41E-08 8.85E-09 4.65E-08

Carbon Monoxide

lb/MMBtu 1.52E-03 2.15E-03 2.43E-03 3.20E-03 1.35E-03

lb/hour 0.3328 0.6239 1.2654 3.3892 2.2246

lb/dscf 7.27E-07 1.10E-06 1.60E-06 2.25E-06 1.08E-06

System Flow Rates

ft/sec 15.99 21.07 34.05 64.30 90.52

ACFM 10,128 13,350 21,574 40,740 57,355

DSCFM 7,634 9,477 13,193 25,076 34,477

Moisture Content (%Volume) 12.50 13.59 17.55 16.53 18.03

Sample Location Temp (oF) 153 183 252 256 260

Table 7. No. 2 Oil Efficiency Test Results.

Load % % Excess Air % Boiler Efficiency % Steam Injection Loss

Minimum Load 76.34 83.74 +0.10

25 67.12 85.19 +0.07

50 25.16 87.09 +0.02

75 20.52 87.29 -0.01

100 17.20 87.70 +0.001

Table 6. Natural Gas Efficiency Test Results.

Load % % Excess Air % Boiler Efficiency % Steam Injection Loss

Minimum Load 30.35 81.48 +0.22

25 18.90 83.65 +0.15

50 9.70 84.66 +0.06

75 10.65 84.43 +0.01

100 6.00 85.00 +0.03


14

Table 8. Fuel Ultimate Analysis (As Received).

Product No. 2 Oil Natural Gas

Carbon (%Wt) 85.44 73.42

Hydrogen (%Wt) 12.19 23.85

Sulfur (%Wt) 0.60 0.00

Oxygen (%Wt) 1.21 2.02

Nitrogen + Chlorine (%Wt) 0.43 0.70

Ash (%Wt) 0.03 0.00

Moisture (%Wt) 0.10 0.00

Heat of Combustion (Btu/lb) 18,765 22,936

Heat of Combustion (Btu/ft3 ) — 1034

Heat of Combustion (Btu/gal) 149,141 —

Symbol (Units) Minimum Load 25% load 50% load 75% load 100% load

Time of Day 11:35 16:25 17:34 18:39 20:36

12:20 17:15 18:14 19:19 21:55

Gas Volume-dry, std. Vmstd (ft3) 32.37 27.92 27.84 27.68 54.57

Condensate Vapor Vol. Vwstd (ft3) 9.08 9.03 7.54 7.63 12.17

Gas Stream Moisture Bws (vol. dec) 0.2190 0.2443 0.2130 0.2161 0.1823

Mol.Wt-flue gas (dry) Msd (lb/lb mo.) 29.44 29.66 29.76 29.75 29.80

Mol.Wt-flue gas (wet) Ms (lb/lb mo.) 26.94 26.81 27.26 27.21 27.65

Flue Gas Velocity Vs (ft/sec) 10.92 16.11 29.36 48.89 53.13

Flue Gas Volume-Actual Qs (acfm) 6,919 10,204 18,604 30,974 33,660

Flue Gas Volume-Std. Qs (dscfm) 4,218 6,356 11,251 18,153 20543

Concentrations Cs

Probe (gr/dscf) na na na na 0.0018

Filter (gr/dscf) na na na na 0.0023

Total Particulate (gr/dscf) na na na na 0.0041

NOx (lb/dscf) 1.94E-06 3.02E-06 3.06E-06 3.10E-06 3.62E-06

VOC (lb/dscf) 0.00E+00 1.13E-08 4.46E-09 1.11E-08 1.8E-08

CO (lb/dscf) 8.07E-07 1.49E-06 1.23E-06 8.36E-07 1.27E-06

Emission Rate E

Probe (lb/hr) na na na na 0.3187

Filter (lb/hr) na na na na 0.4033

Total Particulate (lb/hr) na na na na 0.7219

NOx (lb/hr) 0.4915 1.1521 2.0634 3.3749 4.4593

VOC (lb/hr) 0.0000 0.0043 0.0030 0.0121 0.0222

CO (lb/hr) 0.2041 0.5681 0.8289 0.9102 1.5674

Isokinetic Rate I (%) na na na na 83.21

Table 9. Detailed Gas Fired Emission Test Results (Moisture and Particulate).


15

Symbols (Units) Minimum Load 25% Load 50% Load 75% Load 100% Load

Time of Day 09:03 10:05 11:36 13:30 15:21

09:48 10:45 13:00 14:05 15:51

Gas Volume-dry, std. Vmstd (ft3) 27.20 26.11 42.75 26.11 46.37

Condensate Vapor Vol. Vwstd (ft3 ) 3.89 4.10 9.10 5.17 10.20

Gas Stream Moisture Bws (vol.dec) 0.1250 0.1359 0.1755 0.1653 0.1803

Mol.Wt-flue gas (dry) Msd (lb/lb mo.) 29.37 29.38 29.55 29.60 29.71

Mol.Wt-flue gas (wet) Ms (lb/lb mo.) 27.95 27.84 27.53 27.68 27.60

Flue Gas Velocity Vs (ft/sec) 15.99 21.07 34.05 64.30 90.52

Flue Gas Volume-Actual Qs (acfm) 10,128 13,350 21,574 40,740 57,355

Flue Gas Volume-Std. Qs-Std (dscfm) 7,634 9,477 13,193 25,076 34,477

Concentrations Cs

Probe gr/dscf na na 0.0022 na 0.0026

Filter gr/dscf na na 0.0029 na 0.0146

Total Particulate gr/dscf na na 0.0052 na 0.0173

NOx lb/dscf 3.72E-06 4.27E-06 5.84E-06 7.07E-06 6.36E-06

VOC lb/dscf 0.00E+00 8.85E-09 8.41E-08 8.85E-09 4.65E-08

CO lb/dscf 7.17E-07 1.10E-06 1.60E-06 2.25E-06 1.08E-06

Emission Rate E

Probe lb/hr na na 0.25 na 0.78

Filter lb/hr na na 0.33 na 4.33

Total Particulate lb/hr na na 0.58 na 5.10

NOx lb/hr 1.7035 2.4305 4.6227 10.64 13.1648

VOC lb/hr 0.0000 0.0050 0.0665 0.0100 0.0961

CO lb/hr 0.3328 0.6239 1.2654 3.3900 2.2246

Isokinetic Rate I (%) 101.7 84.4

Table 10. Detailed No. 2 Oil Fired Test Results (Moisture and Particulate).

For More Information

FEMP Help Desk(800) 363-3732International callers please use(703) 287-8391Web site: www.eren.doe.gov/femp

General Contacts

Ted CollinsNew Technology Demonstration Program ManagerFederal Energy Management ProgramU.S. Department of Energy1000 Independence Ave., SW, EE-92Washington, D.C. 20585Phone: (202) 586-8017Fax: (202) [email protected]

Steven A. ParkerPacific Northwest National LaboratoryP.O. Box 999, MSIN: K5-08Richland, WA 99352Phone: (509) 375-6366Fax: (509) [email protected]

Technical ContactEvelyn BaskinOak Ridge National LaboratoryP.O. Box 2008, MS-6070 Bldg 3147Oak Ridge, TN 37831-6070Phone: (865) 574-2012Fax: (865) [email protected]

Produced for the U.S. Departmentof Energy (DOE) by the Oak RidgeNational Laboratory

DOE/EE-0217

May 2000


Printed with a renewable-source ink on paper containing at least 50% wastepaper, including 20% post consumer waste

DisclaimerThis report was sponsored by the United States Department of Energy, Office of Federal Energy ManagementPrograms. Neither the United States Government nor any agency or contractor thereof, nor any of their employees,makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness,or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringeprivately owned rights. Reference herein to any specific commercial product, process, or service by trade name, mark,manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring bythe United States Government or any agency or contractor thereof. The views and opinions of authors expressedherein do not necessarily state or reflect those of the United States Government or any agency or contractor thereof.

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